Cartridge for moist wipes

ABSTRACT

There is provided a cartridge for dispensing wet wipes and for use with or in a dispensing system. The system may include a housing, a tray and a cartridge. The cartridge may have a durable cover over a portion of the cartridge opening, which may be covered with a bacterial resistant seal.

[0001] This application is a continuation in part of pending U.S.application entitled Container for Wet Wipes, Ser. No. 09/659,283,attorney docket no. 659/707 filed Sep. 12, 2000, which is a continuationin part of pending U.S. application entitled System and Dispenser forDispensing Wet Wipes, Ser. No. 09/565,227, attorney docket no. 659/648filed May 4, 2000, which is a continuation in part of pending U.S.application entitled Dispenser For Premoistened Wipes, Ser. No.09/545,995, attorney docket no. 659/623, which was filed on Apr. 10,2000, the disclosures of which are hereby incorporated by reference.

BACKGROUND

[0002] Wet products such as wet wipes have many applications. They maybe used with small children and infants when changing diapers, they maybe used for household cleaning tasks, they may be used for cleaninghands, they may be used as a bath tissue, they may be used as by acaregiver to clean a disabled or incontinent adult, or they may be usedin and for a whole host of other applications, where it is advantages tohave a wipe or towel that has some wetness or moisture in it.

[0003] Wet wipes have been traditionally dispensed in sheet form from atub like container with a hinged lid on the top. The lid is opened andindividual or singularized sheets of the wipes are removed. Another typeof container that has been used for wet wipes provides a roll of wipesin which the wipes are pulled from the top of the container in adirection that is parallel to the axis of the roll. These wipes arepulled from the center of a hollow coreless roll that has perforatedsheets. These containers generally have a snap top lid that is opened toexpose a piece of the wipes that can then be pulled to remove thedesired amount of wipes. Once pulled out the wipes can then be torn off,usually at a perforation, and the lid closed.

[0004] Wet wipes can be any wipe, towel, tissue or sheet like productincluding natural fibers, synthetic fibers, synthetic material andcombinations thereof, that is wet or moist or becomes wet during use orprior to use. Wet wipes may be dispersible when in contact with water ormay be non-dipsersible. Examples of wet wipes are disclosed inapplication Ser. Nos. 09/564,449; 09/564,213; 09/565,125; 09/564,837;09/564,939; 09/564,531; 09/564,268; 09/564,424; 09/564,780; 09/564,212;09/565,623 all filed May 4, 2000, and application Ser. No. 09/223,999entitled Ion-Sensitive Hard Water Dispersible Polymers And ApplicationsTherefore, filed Dec 31, 1998 the disclosures of which are incorporatedherein by reference. Embodiments of dispensers are described inapplication Ser. Nos. 09/565,227 and 09/545,995; in application Ser.Nos. 09/659,307; 09/659,295; 09/660,049; 09/659,311; 09/660,040;09/659,283; 09/659,284; 09/659,306, filed Sep. 12, 2000; in applicationSer. No. 09/748,618, filed Dec. 22, 2000; in application Ser. No.09/841,323, filed Apr. 24, 2001; in application Ser. No. 09/844,731,filed Apr. 27, 2001; and in application Ser. No. 09/849,935, filed May4, 2001; the disclosures of which are incorporated herein by reference.

[0005] There is a need for disposable containers for wet wipes which areused to dispense the wipes which are originally present in thecontainer, and which can be subsequently discarded. Ideally, thedisposable container is not used for more than one set of wipes in orderto minimize the possibility of contamination of the wipes.

SUMMARY

[0006] In an embodiment of the invention there is provided a containerfor wet wipes, comprising a cartridge comprising a first opening havinga first rectangular clearance; the first rectangular clearance having afirst length and a first width; a moisture-loss preventing seal; and apermanently attached cover over a portion of said opening; wherein saidpermanently attached cover forms a second opening having a secondrectangular clearance; the second rectangular clearance having a secondlength and a second width.

[0007] These embodiments may further comprise a container wherein thesecond length is less than about 90% of the first length, the secondlength is less than about 75% of the first length, the second length isless than about 60% of the first length, and the second length is lessthan about 50% of the first length; wherein the second width is lessthan about 90% of the first width, the second width is less than about75% of the first width, the second width is less than about 60% of thefirst width, and the second width is less than about 50% of the firstwidth; wherein the second length is less than about 90% of the firstlength and the second width is less than about 90% of the first width,the second length is less than about 75% of the first length and thesecond width is less than about 75% of the first width, the secondlength is less than about 60% of the first length and the second widthis less than about 60% of the first width, and the second length is lessthan about 50% of the first length and the second width is less thanabout 50% of the first width; and wherein the container furthercomprises a roll of wet wipes.

[0008] In an embodiment of the invention there is provided a containerfor wet wipes, comprising: a cartridge comprising an interior and anopening; the opening having a first rectangular clearance; the firstrectangular clearance having a first length and a first width; a roll ofwet wipes in said interior; and a permanently attached cover over aportion of said opening; the permanently attached cover forming a secondopening having a second rectangular clearance; the second rectangularclearance having a second length and a second width; wherein the roll isretained in the interior; and the wipes can be removed from the interiorby unwinding the roll.

[0009] These embodiments may further comprise a container wherein thesecond length is less than about 90% of the first length, the secondlength is less than about 75% of the first length, the second length isless than about 60% of the first length, and the second length is lessthan about 50% of the first length; wherein the second width is lessthan about 90% of the first width, the second width is less than about75% of the first width, the second width is less than about 60% of thefirst width, and the second width is less than about 50% of the firstwidth; wherein the second length is less than about 90% of the firstlength and the second width is less than about 90% of the first width,the second length is less than about 75% of the first length and thesecond width is less than about 75% of the first width, the secondlength is less than about 60% of the first length and the second widthis less than about 60% of the first width, and the second length is lessthan about 50% of the first length and the second width is less thanabout 50% of the first width.

[0010] These embodiments may yet further comprise a container whereinthe permanently attached cover is configured as a strip; wherein thepermanently attached cover is configured as a plurality of cornercovers; wherein the permanently attached cover is configured as asemicircular cover; wherein the permanently attached cover comprisesbuttons and the cartridge comprises button holes, the buttons and buttonholes coordinating to lock the permanently attached cover to thecartridge; wherein the container further comprises a moisture-losspreventing seal; and wherein the moisture-loss preventing seal coversthe second opening and is removably adhered to a portion of thepermanently attached cover.

[0011] In an embodiment of the invention there is provided a containerfor wet wipes comprising: side walls having a top and a bottom; eachside wall having a length and a depth; the tops of the side wallsforming an opening having a first length and a first width; two opposedside walls corresponding to the first length of the container; a bottomwall joined to each side wall; the bottom wall having an curved sectionand a planar section; the curved section having a first side and asecond side; the planar section having a first side and a second side;the first side of the curved section being joined to the bottom of afirst side wall; the second side of the curved section being joined tothe first side of the planar section; the second side of the planarsection being joined to the bottom of a second side wall that is opposedto the first side wall; a lip; the lip joined to the top of a side wall;the lip extending outwardly at least about 5 mm from the top of a sidewall; a permanently attached cover contacting at least a portion of thelip; and a moisture-loss preventing cover contacting at least a portionof the lip.

[0012] These embodiments may further comprise a container wherein thepermanently attached cover provides a rectangular clearance having asecond length and a second width and wherein the second length is lessthan about 75% of the first length, the second width is less than about75% of the first width, and the second length is less than about 75% ofthe first length and the second width is less than about 75% of thefirst width. These embodiments may yet further comprise a containerwherein the curvature of the bottom wall is about 42 to about 44degrees; wherein the curvature of the bottom wall is about 40 to about45 degrees; wherein the side walls corresponding to the width wisedimension of the container are tapered from the bottom toward the top,such that the distance between them is less at the bottom of thecontainer; wherein the container comprises a rib; and wherein thecontainer comprises a plurality of ribs, the ribs extending along thefirst wall, the curved bottom section, the planar bottom section and atleast partially along the second wall.

[0013] In an embodiment of the invention there is provided a dispensingsystem for wipes, comprising: a dispenser, the dispenser comprising aninterior; and a container shaped to fit into the interior; the containercomprising a cartridge, a permanently attached cover, a plurality of wetwipes, and a moisture-loss preventing seal.

[0014] These embodiments may further comprise a dispensing systemwherein the cartridge comprises a first opening having a firstrectangular clearance, the first rectangular clearance having a firstlength and a first width; the permanently attached cover is situatedover a portion of said first opening to form a second opening having asecond rectangular clearance, the second rectangular clearance having asecond length and a second width.

[0015] These embodiments may yet further comprise a dispensing systemwherein the second length is less than about 90% of the first length andthe second length is less than about 60% of the first length; whereinthe second width is less than about 90% of the first width and thesecond width is less than about 60% of the first width; wherein thesecond length is less than about 75% of the first length and the secondwidth is less than about 75% of the first width; wherein the dispensingsystem further comprises a roll of wet wipes; wherein the interior andthe container are shaped to fit in a single orientation; and wherein thedispenser, the cartridge, and the permanently attached cover togetherare capable of maintaining at least 95% of the moisture of wet wipes fora 14 day period at 73° F. and 50% relative humidity.

DRAWINGS

[0016]FIG. 1 is a perspective view of a dispenser.

[0017]FIG. 2 is an exploded view of a dispenser and cartridge.

[0018]FIG. 3 is a perspective view of an open dispenser.

[0019]FIG. 4 is a top view of a dispenser.

[0020]FIG. 5 is a front view of a dispenser.

[0021]FIG. 6 is a bottom view of a dispenser.

[0022]FIG. 7 is a side view of a dispenser.

[0023]FIG. 8 is a back view of a dispenser.

[0024]FIG. 9 is a perspective view of a dispenser with a wet wipe.

[0025]FIG. 10 is a perspective view of a dispenser, a cartridge and aroll of wet wipes.

[0026]FIG. 11 is a perspective view of a roll of wet wipes FIG. 12 is across section view of a dispenser, a cartridge and a roll of wet wipes.

[0027]FIG. 13 is a cross section view of a cartridge and a roll ofpremoistened wipes.

[0028]FIG. 14 is a cross section view of a cartridge.

[0029]FIG. 15 is a perspective view of the outside of a cover.

[0030]FIG. 16 is a front view of the outside of a cover.

[0031]FIG. 17 is a perspective view of the inside of a cover.

[0032]FIG. 18 is a cross section view of a cover.

[0033] FIGS. 19-24 are views of a wiper assembly.

[0034]FIG. 21 is a cross section view along line A-A of FIG. 19.

[0035]FIG. 23 is a cross section view along line A-A of FIG. 22.

[0036]FIGS. 25A and 25B are perspective views of a cartridge having ahinged lid.

[0037]FIGS. 26A and 26B are diagrammatic views of a cartridge having ahinged lid.

[0038] FIGS. 27-28 are views of a wiper.

[0039] FIGS. 29-31 are views of a cartridge.

[0040]FIG. 32 is a top view of a package of cartridges.

[0041]FIG. 33 is a front plan view of a wiper assembly.

[0042]FIG. 34 is a rear plan view of a wiper assembly.

[0043]FIG. 35 is a plan view of a wiper blade.

[0044]FIG. 36 is a cross-sectional view of a wiper blade.

[0045]FIG. 37 is a perspective view of a wiper blade.

[0046]FIG. 38 is a cross-sectional view of a dispenser.

[0047]FIG. 39 is a cross-sectional view of a portion of a dispenser.

[0048]FIG. 40 is a perspective view of the inside of a cover.

[0049]FIG. 41 is a top view of the inside of a cover.

[0050]FIG. 42 is a view of a conventional bath tissue holder.

[0051]FIG. 43 is a view of a conventional bath holder.

[0052]FIG. 44 is a view of a mounting assembly in a conventional bathtissue holder (shown without the dispenser).

[0053]FIGS. 45A and 45B are side cross section views of a cartridge.

[0054]FIGS. 46A and 46B are side cross section views of a cartridge.

[0055]FIG. 47 is a perspective view of a cartridge.

[0056] FIGS. 48-58 are perspective views of a cartridge having apermanently attached cover over a portion of the opening.

DETAILED DESCRIPTION

[0057] A system and method for dispensing and providing wipes isprovided, which in general may have a housing, a cover, and a cartridgehaving a roll of wet wipes. The cartridge is placed in the housing andthen the wipes can be removed from the dispenser.

[0058] In general there is provided a device for mounting a wet wipesdispenser to another surface. That surface may be, by way of example, awall in a bathroom, a kitchen wall, or a bathroom vanity wall. Thedevice may be used with, or adapted for use with, most any type of wetwipes dispenser, such as the various dispensers illustrated anddisclosed herein. The device is ideally adapted to work in conjunctionwith a conventional bath tissue holder to permit a dispenser to besecurely, yet removably attached to the wall. A conventional bath tissueholder is the type that is typically found in a home. Such holders haveposts that protrude from the wall and a rod or roller that is positionedbetween the posts. These holders may also be partially recessed into thewall. Such a holder and a holder with a mounting assembly engaged areillustrated in FIGS. 42-44. The device may also be used in the absenceof a conventional bath tissue holder and may be adapted to provide thatthe dispenser is fixed to the wall.

[0059] For example, the system may have a dispenser that has a housing,which is capable of being mounted to a surface, such as a wall, acabinet, an existing bath tissue dispenser, a toilet, a toilet tank, astall wall, or a dashboard of an automobile. The dispenser has aninterior that holds a cartridge, which contains the wet wipes. Thesecartridges are sealed and may be grouped in packages of multiplecartridges. Thus, a package of cartridges may be provided to a user. Theuser may then select and open one of the cartridges, put it in thedispenser, and use the wipes as needed. When the wipes are used up, theuser may simply discard the old cartridge and replace it with a new one.Thus, this system enables the user to conveniently obtain and keepseveral cartridges of wipes on hand and then use the wipes as needed. Byusing sealed cartridges to refill the dispenser the user is using a newand fresh product each time and a product that is in contact with freshsurfaces. In general the dispenser system illustrated herein can be usedwith or without conventional dry toilet or bath tissue. If conventionaltissue is used with wet wipes it could be positioned in a side-by-sidemanner, above, or below the wet wipes.

[0060] By way of example, referring to FIGS. 1 through 8, there isprovided a dispenser 1, which has a housing 2, a tray 3, a cover 7, anda mounting assembly 8. The tray and the cover form a gap 4, throughwhich a wet wipe can extend. That portion of the wipe extending throughthe gap may be referred to as a tail. The tray and cover additionallyhave recesses 5, that form an indentation that provides a finger hold,or point where a user can grasp the wet wipe to pull it from thedispenser. The housing may further have an opening 28 for receiving apin 27 on the tray 3. Although optional, this dispenser is also providedwith a roller 6 for mounting and dispensing a roll of another product,such as dry or conventional bath tissue. FIGS. 1 and 4-8 show thedispenser with the cover closed. FIG. 2 shows the dispenser and acartridge in a exploded view. FIG. 3 shows the dispenser assembled andin a fully opened condition. The fully opened condition provides accessto screw 9.

[0061] The housing may be made from any suitable material, such asplastic, wood, ceramic, porcelain, glass, paper, metal, thermoplasticelastomers, or composite materials. For example, polypropylene,polyesters such as polybutylene terephthalate (Pbt), Pbt glass filled,Pbt 15% glass filled, fiberglass, carbon fiber, andacrylonitrile-butadiene-styrene (ABS) may be used to make the housing.

[0062] The housing may have different shapes and sizes. When thedispenser is intended for use in a home it is desirable that it be of asize that is similar to conventional bath tissue roller mounts. It isparticularly desirable that the dispenser be as compact as possible forhome use. Further if the cover is in the range of from about 4-½ inches(114.3 mm) to 6-⅞ inches (174.6 mm) in width it will be able toaesthetically fit in or mount to the vast majority of toilet paperholders that are in existing houses. Preferably the width of the covermay be greater than about 3 inches (76.2 mm), less than about 6 inches(152.4 mm), less than about 7 inches (177.8 mm), and less than about 8inches (203.2 mm). The 4-½ inches (114.3 mm) by 6-⅞ inches (174.6 mm)size provides an added benefit of enabling one size of dispenser to beused in the vast majority of applications in the home. Smaller sizes maybe desirable for certain applications or aesthetic reasons, such as asmall bathroom. The dispenser and its components may have varied colors,such as the almonds and whites that are seen in porcelain bath fixturesor may have any other desirable color. When the housing is used forindustrial or institutional purposes or in commercial applications itmay be desirable to make the housing substantially larger and able tohold substantially more rolls of either or both wet and dry wipes andtissue.

[0063] The housing may be configured as shown in FIG. 1 to mount onto orinto a conventional wall mount toilet paper holder. It may also bemounted directly to a wall, for example by way of a screw, throughmounting hole 30, or by other means of fixing the housing to a wall orsurface, such as glue, nails, screws, rivets, magnetic attachments,staples, engaging brackets and pressure mountings against the sides of aconventional wall mount for toilet tissues. The housing also may have alock 13 that engages a tab 12 on the cover to keep the cover closed, yetprovide an easy way to open the dispenser. Various other ways to lock orfix the cover to the housing may also be employed. For example, a lockand key approach may be desirable in commercial applications or houseswhere there are small children present.

[0064] The cover 7 may be made of any similar material to the housing;it may be the same as or a different material from the housing. Thecover may be clear or have a window for viewing the amount of wet wipesthat remain in the dispenser. It is noted, however, that because thecover is in direct contact with the wet wipe, the cover forms the top ofthe cartridge when the cartridge is inserted into the dispenser and thecover closed, and wood or any other material that would supportbacterial growth would not be favored. It is preferred that allmaterials that are in contact with the wet wipes be made from materialsthat discourage, or do not support bacterial growth.

[0065] Moreover, anti-bacterial agents, medicinal, botanical or skin andhealth agents may be added to the materials that are used to constructthe components of the dispenser system, including by way of example thedispenser housing, the tray, the wiper blade, the wiper assembly, thecartridge, the cover and the gaskets. In particular any component thatis in contact or associated with the wet wipes may have such an agentadded to it.

[0066] The cover is designed to cooperate with the cartridge 11 to forma barrier to moisture loss from the wet wipes. The cover may also bedesigned to cooperate with other components of the dispenser system toform a moisture barrier. The dispenser can maintain wet wipes in a moistcondition when fully closed for at least 1 day, for at least 2 days, forat least 5 days and for at least 14 days, and preferably for more than14 days at room conditions of 73° F. (22.8° C.) and 50% relativehumidity. The dispenser when fully closed can maintain at least about15%, at least about 20%, at least about 25%, at least about 50%, and atleast about 95% of the moisture of the wipes for a 14 day period at 73°F. (22.8° C.) and 50% relative humidity. These moisture retention valuescan be obtained with a tail of the wipe protruding through the gap, thetail having a length of not more than 1.5 inches (38.1 mm).

[0067] The cover may further be designed to cooperate with the cartridge11, or other components of the dispenser system, to form a barrier tocontamination of the wipes within the dispenser. Thus, the cover incooperation with the cartridge, or other components of the dispensersystem, may form a barrier to dirt, dust, mold spores and bacteria.

[0068] The space between the inner surface of the front cover and thesurface of the lip of the cartridge may vary between about 2 mm andabout 10 mm. In this way there is formed a dome above an open cartridgethat at least partially covers that opening, which dome is preferablyless than about 15 mm, less than about 10 mm, less than about 5 mm andideally is less than about 2 mm above the lip of the cartridge. Theheight of the dome may also be measured from the surface of a full rollof wet wipes in which an additional 2 to 7 mm may be added to the heightof the dome. Higher domes may also be employed, but such higher domesmay be less aesthetically pleasing and may provide for greater amountsof evaporation or moisture loss from the wet wipes.

[0069] The cover may be provided with an inside rim 33 (see, e.g., FIG.3) and a wiper 10 (see, e.g., FIGS. 2 and 3). The cover inside rim andwiper cooperate with the lip 31 of the cartridge. In this way when thecover is closed the inside rim is brought against the lip of thecartridge and the wiper is similarly brought against the tray includingthe guides, as well as the lip of the cartridge. In a furtherembodiment, the cover may be provided with a lip, and the cartridge maybe provided with a rim to facilitate the cooperation.

[0070] The distance between the inside of the cover where the wiper islocated and the tray may be less than the height of the wiper blade.Thus, in this configuration the wiper blade would be placed undercompression against the lip, the tray, or the guides 16 or all of themdepending on the position of the wiper. Here the wiper blade would exertpressure on the wet wipes. The wiper may also be positioned so that itcontacts the wet wipe but does not exert pressure against it, or bepositioned so that it is a short distance above the wet wipe. The amountof pressure that the wiper exerts on the wet wipe may vary dependingupon several factors, including the purpose for the wiper, the materialthat the wiper blade is made from, the material that the wet wipe ismade from and the material that the cartridge lip 31 is made from.

[0071] The tray 3 may be made from any similar material to the housingor cover, and it may be the same material or different material fromthose of components. The tray may have side walls 22, 23, 80 and 81.Walls 22 and 23 correspond to the sides of the dispenser, wall 80corresponds to the top of the dispenser, and wall 81 corresponds to thebottom of the dispenser. The tray shown in the figures does not have aback wall, although one may be provided if desired. The side walls maybe provided with recesses 24, 25, and 26. These recesses cooperate withprotrusions 19, 20 and 21 on the cartridge (19 with 26, 20 with 24 and21 with 25). In this way the cartridge is securely, yet easily removablyheld in the dispenser. The tray opening 15 is sized in relation to thecartridge (or the cartridge may be sized in relation to the trayopening) so that the cartridge can easily be slid into and out of thedispenser.

[0072] The tray and cartridge together result in a keyed typearrangement that allows the cartridge to be inserted fully or properlyin only one orientation into the dispenser. Thus the two elements fittogether in a manner similar to a lock and key. This assures that theroll of wipes will unwind from a predetermined orientation, i.e., fromthe bottom of the roll or the top of the roll. As is apparent from FIG.2 the tray opening and cartridge are not symmetrically shaped. Thisasymmetry provides for the keyed arrangement. An object is consideredsymmetrical if there can be a plane which passes through the object suchthat the portions on either side of the plane are reflections of eachother.

[0073] In the embodiment shown in FIG. 2 the asymmetry in the verticalplane is obtained by having a different number and location ofprotrusions and recesses on opposite sides. It is recognized that anysuitable means to accomplish asymmetry may be employed, such as notches,tongue and groove, or the shapes of the opening and detents. Forexample, some of the cartridge walls may be flat while others arerounded, or the cartridge lip may be non-planar. Additionally, labelingor marking of the cartridge, the tray, or both can create the effect ofasymmetry. This latter approach requires the effort of the user, whereasthe former approach is designed to be “user proof.” The housing mayfurther have guides 16. The guides may be movable or fixed. The guidesmay have raised surfaces and lowered surfaces. These guides may be madefrom the same type of material as the housing. They may be integral withthe housing. The guides and the housing may be one continuous piece ofplastic. The guides may be designed to cooperate with the wiper toprevent or reduce the tendency of the wipe to skate to one side of thedispenser as the wipe is pulled out and torn off. The guides may alsocooperate with the wiper to regulate and control the amount of drag. Thetray may have barbs 71 to discourage the placement of wet wipes directlyinto the dispenser without the use of a protective package, a practicewhich could cause premature drying of the wet wipes or could allow thegrowth of bacteria and/or mildew in the wipes.

[0074] The cartridge may be made out of any suitable material, such asplastic. It is desirable that the cartridge be made from a light weight,inexpensive, disposable and recyclable material. The cartridge has sidewalls 17, 18, 39 and 40 and bottom wall 41. The cartridge has a lip 31that forms an opening at the top of the cartridge. The cartridge hasribs 32. The ribs may extend part way or all the way along the sides 39and 40 and the bottom 41. The ribs 32 may cause grooves or indentationsto form in the rolls, depending on the density of the roll andconditions of use. These grooves are not necessary to the use of thedispenser system. The curvature of the cartridge bottom is between 40and 45 degrees, preferably between 42 and 44 degrees.

[0075] The cartridge may be any shape or size provided that it fits inor cooperates with the dispenser. For example a cartridge that would beuseful for application in the home would have side walls 17 and 18 thatare less than 105 mm in length and side walls 39 and 40 that are lessthan 134 mm in length.

[0076] Instead of protrusions 19, 20 and 21, the cartridge may haverecesses at those locations, and the tray may have correspondingprotrusions. Moreover, the cartridge may have ribs, like rib 32, alongside walls 17 and 18.

[0077]FIG. 9 shows a dispenser in the closed condition with a tail of awet wipe 36 protruding from gap 4 into the finger hold indentation thatis formed by recess 5. In use the tail of the wet wipe would be graspedand pulled generally in the direction of arrow 35 causing the roll tounwind and the wipe to be dispensed from the dispenser. In use the wetwipe may also be subjected to forces tangential and perpendicular to thedirection of arrow 35. If these forces occur the guides and the wiperhelp to prevent the wipe from skating to one side of the gap andbunching up or binding.

[0078]FIG. 10 is an exploded view of a dispenser, cartridge and roll ofwipes 34 showing the relationship of these components.

[0079]FIG. 11 shows a roll of wipes 34 that has a tail 36 and furtherdefines the axis of the roll as 37. Rolls useful with this dispenser oras part of a dispensing system may contain from as little as a fewlinear inches (or cm) to more than 450 linear inches (11.43 m), to morethan linear 600 inches (15.24 m) to more than a thousand linear inches(25.40 m) of wet wipes. The rolls may have a web of material that mayhave any number of sheets. Usually, the sheets are separated byperforations that enable the sheet to be easily torn from the web butare strong enough that they will not separate while the web is beingpulled from the dispenser. An example of a roll that is particularlyuseful for applications in the home is one that has a diameter of about2 inches (50.8 mm) to about 3 inches (76.2 mm), of about less than 5%inches (139.7 mm), and preferably has a diameter of about 3 inches (76.2mm) and more preferably of about 2-⅞ inches (73.0 mm). This roll hasfrom about 400 linear inches (10.16 m) of wipes to about 1000 linearinches (25.40 m) of wipes. Without limitation, each sheet length may befrom about 3 inches (76.2 mm) to about 10 inches (254.0 mm) andpreferably are about 4.5 inches (114.3 mm). This roll may further have adensity of from about 0.3 g/cc to about 1 g/cc, from about 0.5 g/cc toabout 1 g/cc and preferably about 0.62 g/cc. A particular example of aroll may be one having a diameter of about 2 inches (50.8 mm) andcontaining about 450 linear inches (11.43 m) of wipe. Another particularexample of a roll may be one having a diameter of about 3 inches (76.2mm) and containing 450 linear inches (11.43 m) of wipes.

[0080] The preferred form of wet wipes for use with the dispenser systemis a solid coreless roll as shown in FIG. 11. It is to be understood,however, that cored rolls (hollow cores, solid cores and partially solidcores), hollow coreless rolls, and stacks of sheets may also be used inthe dispenser system. When density values are referred to herein, it isfor the density of the roll and this would exclude any void, for acoreless hollow roll, or space occupied by a core for a cored roll.

[0081] Various tests and observations of physical properties arereported in Tables I, II, III, and IV.

[0082] Solution add-on level is the amount of solution by weight dividedby the amount of dry wipe by weight multiplied by 100 to provide apercentage value.

[0083] Base sheet converting refers to the width of the roll and thesheets in the roll, i.e., along axis 37 of the roll in inches.

[0084] Perforation refers to the amount of cutting and the distancebetween the cuts in the perforation that separates the sheets in a roll.There are three parameters to this measurement: cut length, bond lengthand bond spacing. The bond spacing is equal to the sum of the cut lengthplus the bond length. By way of example, perforations that are usefulwith wet wipes are ones that have a bond length of 0.02 inch (0.51 mm),a cut length of 0.05 inch (1.27 mm), and a bond spacing of 0.07 inch(1.78 mm), or one that has a bond length of 0.04 inch (1.02 mm), a cutlength of 0.09 inch (2.29 mm) and a bond spacing of 0.13 inch (3.30 mm).

[0085] Dry basis weight is the basis weight of the wipe before thesolution is added to the wipe, i.e., before it is wet.

[0086] Wet thickness is the thickness of a wet wipe, i.e., after thesolution has been added to it, in mm.

[0087] Sheet count is the number of sheets in a roll, i.e., the numberof sheets created by the perforations.

[0088] Although all tests are done under TAPPI standard test conditions,the wet wipes are not equilibrated to those conditions. Instead, thewipes are removed from a sealed container or cartridge and tested withina few, generally less than 5-10, minutes after opening. This is about a5 minute variation in this time period that the wet wipe is exposed tothe atmosphere, which does not materially or significantly alter thetest results.

[0089] Tensile, stretch and TEA (total energy absorbed) values wereobtained on the wet product following ASTM 1117-80, section 7, with thefollowing modifications: sample dimensions were 1+/−0.04 inch(25.4+/−1.0 mm) wide and 4.25+/−-0.04 inches (108.0+/−1.0 mm) wide;initial gauge length was 3 +/−0.04 inches (76.2+/−1.0 mm); test speed is12 inches/minute (305.0 mm/min).

[0090] MD tensile is the peak load before failure per inch width of thesample, as determined in the machine direction. CD tensile is the peakload before failure per inch width of the sample, as determined in thecross direction. MD stretch is the percentage of elongation the wipe hasin the machine direction at the peak load. CD stretch is the percentageof elongation of the wipe in the cross machine direction at the peakload. Total Energy Absorbed (TEA) is the area under the force-elongationcurve (in units of lb. and ft., respectively) from the start to thefailure point divided by the initial surface area of the sample betweenthe upper and lower grips. For these samples, this surface area was 3sq. inches (19.4 cm²). Ten specimens were tested for each code, and theaverage was calculated and reported. The test can be carried out on astandard tensile tester such as a MTS Sintech 1/G test machine withTestWorks 3.10 software. Both the Sintech test machine and the TestWorkssoftware are available from MTS Corporation located at 1400 TechnologyDrive, Eden Prairie, Minn.

[0091] Detach refers to the force in grams per sheet that is required tobreak a perforation, i.e., the amount of force required to separate twosheets in a roll along the perforation. These properties were determinedusing a MTS Sintech 1/G test machine with TestWorks 3.10 software. Twosheets were removed from a roll. The sheets had a width of 4.25 inches(108.0 mm), and were connected by perforations along the width. Thesheets were folded in half along the length such that the width of thesample was 2-⅛ inches (54.0 mm). The top and bottom of the sample wereplaced in grips having an internal spacing of 2 inches (50.8 mm), suchthat the perforation line was centered between the upper and lowergrips. The upper grip was then displaced upward (i.e. away from thelower grip) at a rate of 10 inches/minute (254.0 mm/min) until thesample was broken along the perforations. The applied force and sampleelongation were measured throughout the test. The peak load from theforce-elongation curve is recorded so that the detach strength isexpressed in units of grams/sheet. The average results from ten samplesare reported.

[0092] Percentage strain at peak load (“% strain @ pk load”) wasdetermined from the results of the test described above. The elongationat the peak load is divided by the initial sample length of 2 inches(50.8 mm), and the result is designated the % strain @ peak load. Theaverage results from ten samples are reported.

[0093] Wet thickness refers to the thickness of a wipe that is measuredwhile the sample is subjected to a specified load or weight. The wetthickness of wet wipes and wipes before wetting are reported in TableII. These values are based on samples measuring 3×4 inches (76×102 mm)that were individually placed under a confining load of 0.05pounds/square inch (psi) (345 Pa). The region of the sample that wastested was free of wrinkles and folds. A Starrett Comparator Base Model653G was used to perform these tests available from Starrett, 121Crescent St., Athol, Mass. 01331. This base is precision ground to beflat (tolerance of +/−0.001 inch, +/−0.025 mm). A digital displacementindicator (Sony model U30-1 SET) was attached to the base via acantilevered horizontal control arm supported by a vertical shaft. Theindicator measures vertical displacement relative to the comparator baseto within 0.001 inch (0.025 mm). The load was applied by an acryliccontact foot attached to a vertically traveling spindle shaft thatdescended to the comparator base. The foot has a diameter of 3.00 inches(76.2 mm), a height of 0.63 inch (16.0 mm) and is flat on the lowersurface to a tolerance of +/−0.001 inch (0.025 mm). The weight of thecontact foot, spindle, and the associated hardware, not including thecontact force springs in the indicator, is 160.5+/−0.1 g. The spindleshaft descends to the comparator base with a travel time of 0.5 secondsto 0.75 seconds. The thickness was measured by the indicator as theheight of the wipe relative to the surface of the comparator baseimmediately after the load pressure of 0.05 psi (345 Pa) was applied for3 seconds. Calibration before testing was performed on a set of standardsamples traceable to the National Bureau of Standards.

[0094] By way of example and without limitation, wet wipes useful in thepresent dispensing system may have a dry basis weight from about 10 toabout 200 gsm, a dry thickness from about 0.5 to about 2 mm, a wet(i.e., wipe with solution or wetting material added) thickness fromabout 0.3 to about 0.7 mm, a MD wet tensile at least about 250 g/inch(9.8 g/mm), a CD wet tensile at least about 200 g/inch (7.9 g/mm), a MDwet stretch from about 5% to about 30%, a CD wet stretch from about 5%to about 36%, a TEA MD wet strength of from about 0.5 to 2 ft-1 b/sq.inch (0.10 to 0.4 J/cm²), a TEA CD wet strength of from about 0.5 to 2ft-lb/sq. inch (0.10 to 0.4 J/cm²), and a solution add-on of about150-350%.

[0095] Peel force measures the amount of force in grams/4.25 inches(g/108.0 mm) required to unroll a roll of wet wipes, i.e., the force ingrams required to unroll a roll that is 4.25 inches (108.0 mm) wide.Thus, these values could be normalized to apply to any width roll ingrams/inch of roll width basis. The peel force, as reported in Table IIwas the force required to unroll a roll as it was resting in an opencartridge and was measured with an MTS Sintech 1/G test machine withTestWorks 3.10 software. A 4.5-inch (114.3 mm) wide clamp with rubbersurfaces gripped the tail of a roll, with the roll positioned directlyunderneath the clamp such that the tail would remain vertical as it wasunwound from the roll. The clamp was attached to the crosshead, whichpulled the tissue web upward at a speed of 100 cm/minute. Peel force wasmeasured by a 50 Newton load cell. The average load to pull 18 to 20sheets away from the roll was recorded by averaging two runs in which 4sheets each were separated and two runs in which 5 sheets each wereseparated. Only the first 18 to 20 sheets from the roll were used toobtain the measurements of Table II.

[0096] The dispensing force, which is the force to pull the wet wipesfrom the dispenser, may also be determined. This force can be measuredwith a MTS Sintech 1/G test machine equipped with TestWorks 3.10software. A clamp with rubber surfaces grips the tail of a roll of wetwipes placed in a dispenser. The initial distance between the clamp andthe platform where the dispenser sits is about 12 inches (304.8 mm). Thedispenser is placed underneath the clamp. The clamp is attached to thecrosshead, which pulls the roll upward at a speed of 100 cm/min. Thepull force is measured by a 50 Newton load cell. For each run, the pullforce as a function of pull distance curve for pulling 4 sheets awayfrom a roll is recorded using the TestWorks 3.10 software. Based on thecurve, the average pull force for each run is calculated. The averageload of five runs is used to represent the dispensing force of a givenroll. Only the first 23 to 25 sheets from the roll were used to obtainthe measurement.

[0097] Table I sets out types of wet sheets and their properties. InExample 1, the solution was a sufficient amount of commercial (no salt)solution such as that which is used in the commercially availableKLEENEX® brand COTTONELLE® flushable moist wipes product ofKimberly-Clark Corporation. In Example 2, the solution was a sufficientamount of 4% salt water solution such as a simple 4% salt water solutionwith other additives as disclosed in the examples of wet wipeapplications discussed previously in the Background of Invention, all ofwhich have been and are incorporated herein by reference. TABLE INon-Dispersible Dispersible Wet Wipe Example 1 Wet Wipe Example 2 BasisWeight 60 gsm 60 gsm Solution commercial 4% salt (no salt) solu- tionSolution Add 175% 228% on level Basesheet 4.25″ width 4.25″ widthConverting Perforation 0.11″ 0.07″ Bond Spacing Run Average Run STDevRun Average Run STDev Dry Basis 57 2 66 4 Weight (gsm) Wet Thickness0.56 0.02 0.47 0.01 (mm) Sheet Count 99 0.7 99 1.1 Wet tensiles MDTensile 380 26 321 30 (g/in) MD Stretch 23 1.4 28 1.6 (% Elongation) TEA0.96 0.06 1.02 0.07 (Ft-Lb/Sq.In) CD Tensile 329 28 287 29 (g/in) CDStretch 28 1.8 34 3.5 (% Elongation) TEA 0.93 0.09 0.97 0.13(Ft-Lb/Sq.In) Detach 752 21 853 34 (g/sheet) % strain 8 0.5 11 1.1 @ pkload

[0098] Table II contains additional data reflecting the properties ofdisposable wet wipes. This table shows the effects that changing basesheet and solution variables has on the physical properties of thewipes. The pulp used to make these sheets was Weyerhauser CF 405. Forthis example, the binder was example Code E, Table 15, of Ser. No.09/564,531. This binder material had a molecular weight of 610,000 andwas made from the following monomers provided in the following weightpercents: 60% acrylic acid, 24.5% butacrylic acid, 10.5%2-ethylhexyl-acrylic acid, and 5% AMPS(2-acrylamido-2-methyl-1-propanesulfonic acid). TABLE II 100% pulp/ 100%pulp/ 100% pulp/ 15% PET/ 65 gsm 60 gsm 55 gsm 55 gsm 22 % binder/ 20%binder/ 20% binder 20% binder/ Basesheet 1.1 mm dry .76 mm dry .76 mmdry .84 mm dry Variables thickness thickness thickness thickness 0.5%silicone; 0.25% lanolin Solutions Example 3 Example 4 Example 5 Example6 MD Wet 500 452 383 391 Tensile (g/1″) CD Wet 445 403 344 310 Tensile(g/1″) wet thickness 0.46 0.40 0.39 0.41 (mm) peel force 167 131 1061.0% silicone; 0.25% lanolin Solutions Example 7 Example 8 Example 9 MDWet 473 401 416 Tensile (g/1″) CD Wet 455 348 350 Tensile (g/1″) wetthickness 0.45 0.40 0.39 (mm) peel force 170 120 115 1.0% silicone; 0.0%lanolin Solutions Example 10 MD Wet 528 Tensile (g/1″) CD Wet 462Tensile (g/1″) wet thickness 0.44 mm peel force 162

[0099] Table III sets out the physical properties of rolls of wet wipesand Table IV sets out the theoretical physical properties of rolls ofwet wipes. TABLE III Coreless Roll Measurements and Calculations UnwoundCalculated Calculated Measured Wet Roll Effective Compression RollDiameter Thickness Density Thickness Factor Number (inches) (mm) (g/cm³)(mm) (%) 1 2.77 NA 0.621 0.340 71% 2 2.83 0.41  0.595 0.355 74% 3 2.86NA 0.583 0.362 76% 4 2.90 NA 0.567 0.373 78% 5 2.96 0.478 0.544 0.38881% 6 2.86 NA 0.583 0.362 76% 7 2.98 NA 0.537 0.393 82% 8 2.88 NA 0.5750.368 77% 9 2.94 NA 0.552 0.383 80% 10 2.86 0.448 0.583 0.362 76% 112.86 NA 0.583 0.362 76% 12 2.84 NA 0.591 0.357 74% 13 3.00 NA 0.5300.399 83% 14 2.86 NA 0.583 0.362 76% 15 2.86 NA 0.583 0.362 76% #diameter²/4 · initial sheet width)

[0100] TABLE IV Theoretical Roll Density Possibilities CalculatedAssumed Assumed Calculated Calculated Basesheet Solution Roll Pre-woundCompression Roll Roll Weight Add-on Weight Wet Thickness Factor DiameterDensity (gsm) (%) (grams) (mm) (%) (inches) (g/cm{circumflex over ( )}3)Footnote 65 225 253 0.48 1.300 3.75 0.34 (1) 65 225 253 0.48 1.150 3.530.38 65 225 253 0.48 1.000 3.29 0.44 (2) 65 225 253 0.48 0.900 3.12 0.4965 225 253 0.48 0.800 2.94 0.55 65 225 253 0.48 0.710 2.77 0.62 (3) 65225 253 0.48 0.600 2.55 0.73 65 225 253 0.48 0.500 2.33 0.88 (4) 65 225253 0.48 0.440 2.18 1.00 65 225 253 0.48 0.405 2.09 1.09 (5) 65 300 3110.48 1.300 3.75 0.42 65 300 311 0.48 1.150 3.53 0.47 65 300 311 0.481.000 3.29 0.54 65 300 311 0.48 0.900 3.12 0.60 65 300 311 0.48 0.8002.94 0.68 65 300 311 0.48 0.700 2.75 0.77 65 300 311 0.48 0.600 2.550.90 65 300 311 0.48 0.500 2.33 1.08 50 225 195 0.48 1.300 3.75 0.26 50225 195 0.48 1.150 3.53 0.29 50 225 195 0.48 1.000 3.29 0.34 50 225 1950.48 0.800 2.94 0.42 50 225 195 0.48 0.600 2.55 0.56 50 225 195 0.480.400 2.08 0.85 50 225 195 0.48 0.313 1.84 1.08 50 150 150 0.48 1.3003.75 0.20 (6) 50 150 150 0.48 1.000 3.29 0.26 50 150 150 0.48 0.800 2.940.33 50 150 150 0.48 0.600 2.55 0.43 50 150 150 0.48 0.400 2.08 0.65 50150 150 0.48 0.300 1.80 0.87 50 150 150 0.48 0.240 1.61 1.09 # exceedingstrength of sheets or perforations

[0101] The dispensing force should be ideally considerably less than thedetach force for a roll of perforated wipes. In this way it is assuredthat the wipes will be able to be pulled from, or removed from, thedispenser without inadvertently breaking the perforation. Thus, adispensing force of from about 100 g to about 600 g is contemplated, adispensing force of from about 150 g to 250 g is further contemplatedand ideally a dispensing force of less than 200 g is desirable, withforces based on g/4.25 inches (g/108.0 mm). Normalized, these forces are23.5 g/inch (0.93 g/mm) to 141.2 g/inch (5.56 g/mm), 35.3 g/inch (1.39g/mm) to 58.8 g/inch (2.32 g/mm), and 47.1 g/inch (1.85 g/mm).

[0102] Generally a peel force of from 80 g -300 g (per 4.25 inches,108.0 mm) is contemplated, although lower peel forces may be obtainedwith different types of wipe products. The cartridge adds minimalresistance to the roll as it is unwound. Thus, the force required tounwind a roll is not materially increased by the cartridge.

[0103]FIG. 12 shows the roll 34 as it is placed in a cartridge in adispenser. The spiral line 38 is intended to represent the manner inwhich the roll is wound and depicts in that configuration a roll that isbeing unwound from the bottom. That figure further shows therelationship of the wiper 10 to the wet web. FIG. 13 shows the roll 34in cartridge 11, with spiral line 38 indicating the wind of the roll.This figure shows the relationship of the roll and the ribs 32. As canbe seen from this figure the roll is lifted off of the side and bottomwalls of the cartridge by rib 32. Thus, the amount of surface area ofthe roll that is in contact with the cartridge is reduced. This reducesthe drag that the roll experiences from friction with the cartridge whenthe roll is turned, thus contributing to a reduced dispensing force.

[0104]FIG. 14 shows a portion of a cartridge 11, the lip 31 of thecartridge, and the side walls 39 and 40 . The angle at which thecartridge is positioned has an effect on how well the dispenser willperform. The angle will have a tendency to increase or reduce the dragassociated with pulling the wipe out. It will have an effect on theamount of siphoning, wicking or drying that may take place in the wetwipe. It may also have an effect on how the roll acts as it is unwound,becoming smaller and smaller in the cartridge. The angle of thecartridge can be measured by the angle that the lip 31 forms with a truevertical axis, shown as 42. For a dispenser system as shown in FIGS.1-12, the angle 43 that the lip 31 has with a true vertical axis 42should be from about 10 degrees to about 80 degrees, from about 20degrees to about 70 degrees, at least greater than 20 degrees, at leastsmaller than 60 degrees, and preferably about 30 degrees.

[0105] Further the angle may be selected such that it balances theforces between the peel forces associated with unrolling the roll andthe weight of the roll forcing it down against the ribs. Thus the wipecan be unrolled without having excessive movement of the roll within thecartridge, which in turn overcomes the tendency of the roll to translatetoward the gap and bind or jam the dispenser. Additionally, theselection of the angle may play a role in reducing the drying of the wetwipe. As the angle 43 is increased the difference between the height ofthe top of the roll and the tail is decreased, thus decreasing anysiphoning driving force.

[0106]FIGS. 15 through 18 show various views of an example of a cover.In this example the cover 7 has cover mounts 29, a recess 5 for formingpart of a finger hold indentation, an inside rim 33, which has a topinside rim section 45 and side inside rim sections 46 (of which only onecan be seen in FIG. 17), leg sections 72, and posts 44. In this examplethe posts are used to connect the wiper to the cover.

[0107] In a further example of the tray, the tray is fixed to thehousing. This may be accomplished by having the housing and tray beingmade out of a single piece of material or having the housing and trayjoined together by a permanent bonding means, such as welding, heatbonding or gluing. In yet a further example the tray may be attached tothe housing so that is cannot rotate with respect to the housing, yetstill may be removable.

[0108] Wiper blades may be made out of any flexible material, such asthermoplastic elastomers, foam, sponge, plastic, or rubber having ashore A durometer hardness value ranging about 0 to 80, from about 15 toabout 70 and preferably from about 30 to about 60. It is furtherpreferred that the wiper blades be made from a material that will form agood moisture and contamination barrier. Examples of preferred types ofmaterial are SANTOPRENE®, Kraton®, silicone, or styreneethylene/butylene styrene (SEBS). The wiper blade is designed tofunction with the guides and the tray and to a limited extent the lip ofthe cartridge. Depending on the placement of the wiper, it could havegreater or lesser interaction with these components of the dispensingsystem. The gap between the end of the wiper blade and the tray may bevaried depending upon the thickness of the wet wipes and how much dragis need for the dispensing system to function as desired. The wiperblade can help to hold the tail of the wipe in place and thus keep thetail from falling back through the gap and into the cartridge. The wiperblade material has a Gurley stiffness value (ASTM D 6125-97) betweenabout 100 mg and 8000 mg, preferably between about 200 mg and 6000 mg,and more preferably between about 400 mg and 3000 mg.

[0109] The force applied to the wipe by the wiper blade when pulling thewipe from the dispenser should not be greater than the tensile strengthof the wipe in the non-perforated region and not greater than theperforation tensile strength of a perforated wipe. If the wipes are madesuch that they are dry in storage and become wet during use, the blademay be configured to exert pressure on the wipe. In this case, thedispensing of a sheet or sheets causes sufficient shear to be applied tothe wipe to permit the moisture to be released. For example, this forceor shear may be sufficient to cause microcapsules of fluid to burst ormay be sufficient to rupture a protective emulsion which contains thefluid.

[0110]FIGS. 19 through 24 show an example of a wiper assembly. In thisexample the wiper assembly 10 comprises a chassis 48, and a blade 50that has fingers 49. In this example the fingers are designed tocooperate with the lowered surfaces of the guides 16 on the housing. Inthis example the blade is made of SANTOPRENE® and the chassis is made ofpolypropylene.

[0111]FIGS. 27 through 28 show an example of a wiper blade. In thisexample the wiper blade is formed of a single piece (see FIG. 27) ofmaterial that is folded over to form the wiper blade (see FIG. 28). Thewiper blade has raised portions 51 that reduce the amount of surfacearea of the wiper blade that contacts the sheet and raised areas 53 andlowered areas 52 that cooperate with the raised and lowered areas of theguides.

[0112] FIGS. 38 to 41 illustrate dispensers 1 that have a rounded member95 or rounded ridges 96. These components are shown as being part of orattached to the wiper blade assembly 99 and adjacent the wiper blade 74.These components prevent or reduce the tendency of the roll from bindingin the gap as the size of the roll decreases.

[0113]FIGS. 33 through 37 show an example of a wiper assembly. In thisexample the wiper comprises a chassis 73, and a wiper blade 74 (74 ashows sections of blade engaging and protruding through the chassis)that has fingers 75. In this example the fingers are designed tocooperate with the lowered surfaces of the guides 16 in the dispenser.In this example the blade is made of SANTOPRENE® and the chassis is madeof polypropylene. This embodiment contains raised or thicker areas 97 ofthe wiper. These raised areas cooperate with the guides 16 on the tray.

[0114]FIG. 42 depicts a conventional bath tissue holder 85 that is thepartially recessed type, having posts 86. FIG. 43 depicts a conventionalbath tissue holder 85 that is not recessed and having posts 86 and aroller 6. FIG. 44 illustrates the holder of FIG. 43 with the rollerremoved and a mounting assembly 8 engaged with the post 86. In actualuse the mounting assembly would be joined with a dispenser, as shown forexample in FIG. 2.

[0115] Alternative mountings may also be employed. These mountings maybe fixed or removable. They may include by way of example such fasteningsystems as cable ties, wing nuts, anchor bolts, click and grooves andsnap and lock mechanisms.

[0116] FIGS. 29-31 show an example of a cartridge. In this example thecartridge has protrusions 69 on its side walls.

[0117]FIG. 32 shows an example of a package of cartridges. In use thispackage would be filled with rolls of wet wipes, one for each cartridge.The cartridges would then be sealed, by placing a removable seal overthe lips 31. The seal is preferably moisture and bacterial resistant.The consumer would then purchase the package and remove a cartridge,open the dispenser and place the cartridge in the dispenser. The sealcan be removed either before placing the cartridge in the dispenser orafter it is inserted in the dispenser. The end of the roll of wet wipesis then pulled out and over the tray and guides and the cover is thenclosed, thus providing an efficient system for dispensing wet wipes.

[0118] The cartridge and the seal cooperate to prevent the loss ofmoisture from the wipes. The cartridge and seal may independently bemade of a suitable material such as plastic, metal foil, or paper, andthey may be made of a single piece of material or they may be laminated.For example, suitable materials include metal foil; plastic-lined metalfoil; plastic-coated paper; plastic-coated cardboard; and plasticsincluding high impact polystyrene (HIPS), polyethylene, polypropylene,polyvinyl chloride, and laminates of plastics such as HIPS/polyvinylchloride/HIPS laminates.

[0119] The cartridge may have a lid or cover with a removable strip.Removal of this strip would result in a space through which the wipescan be dispensed. In this configuration, it may be useful to attach thetail of the wipes to the strip. In this way, removal of the stripfacilitates the threading of the wipes through the gap. The cartridgemay also have a removable seal over the lid or cover.

[0120] Referring to FIGS. 48-58, the cartridge may have a permanentlyattached cover over a portion of the cartridge opening. The permanentlyattached cover and the cartridge opening may be covered by a removablemoisture-loss preventing seal. A permanently attached cover is fixedlyattached to the cartridge such that the cartridge and the cover cannotbe separated as a result of the intended use of the wipes cartridge. Theattachment between the cover and the cartridge is of sufficient strengththat the cartridge and/or cover must be deformed, damaged, or subjectedto extreme environmental conditions in order to separate the cartridgefrom the attached cover.

[0121] The cartridge opening has a rectangular clearance, which isdefined as a rectangle of the maximum length and width which will fitinto the opening when in the plane of the opening. The permanentlyattached cover reduces the rectangular clearance of the opening suchthat the roll can be removed only by unrolling the sheets or by damagingthe cartridge and/or cover. The reduction in the rectangular clearanceserves to convert the cartridge opening into a modified, or second,opening. For some configurations of the permanently attached cover, theoriginal cartridge opening may be converted into more than one secondopening.

[0122] The reduced rectangular clearance, of the second opening, mayhave a length that is less than about 90% of the length of therectangular clearance of the cartridge opening. Preferably, the reducedrectangular clearance has a length that is less than about 75% of thelength of the rectangular clearance of the cartridge opening, morepreferably less than about 60%, more preferably less than about 50%. Thereduced rectangular clearance may have a width that is less than about90% of the width of the rectangular clearance of the cartridge opening.Preferably, the reduced rectangular clearance has a width that is lessthan about 75% of the width of the rectangular clearance of thecartridge opening, more preferably less than about 60%, more preferablyless than about 50%. The reduced rectangular clearance may have both alength and a width that are independently less than about 90% of thecorresponding length and width of the rectangular clearance of thecartridge opening. For example, for a cartridge having an opening with arectangular clearance of length 114 mm and width 76 mm, the length andwidth of the reduced rectangular clearance of a second opening, formedby the presence of a permanently attached cover, may independently beless than about 102 mm and 69 mm respectively, may independently be lessthan about 85 mm and 57 mm respectively, may independently be less thanabout 69 mm and 46 mm respectively, and may be less than about 57 mm and38 mm respectively.

[0123] The permanently attached cover may, for example, be configured asa strip such as 200 (FIG. 48), 201 (FIG. 49), and 202 (FIG. 50).Permanently attached covers such as these serve to divide the cartridgeopening into two openings, each having a reduced rectangular clearance.The permanently attached cover may be configured as a plurality ofcorner covers such as 204 (FIG. 52) and 205 (FIG. 53), which reduce boththe width and the length of the cartridge opening. The permanentlyattached cover may provide only a single opening across the length ofthe cartridge, reducing only the width of the rectangular clearance.Further examples include semicircularly shaped permanently attachedcovers 206 (FIG. 54) and permanently attached covers 203 and 208 (FIGS.51 and 55) which expose the top or bottom half of the roll which isprovided within the cartridge.

[0124] It is desirable that the permanently attached cover has a shape,size, and orientation such that the tail of a roll of wipes which iscontained in the cartridge can be easily accessed by a user. For thisreason, it may be desirable for the permanently attached cover toprovide access to more than half of the width of the opening (see FIGS.48-50, and 52-54). Access to the tail of a roll of wipes may beespecially desirable when the package of wipes is first opened, or whena portion of the wipes has been separated from the roll in such a waythat the tail of the roll of wipes is contained within the cartridge andis not visible along the entire length of the second opening.

[0125] The permanently attached cover may be rigid or flexible; it maybe transparent, opaque, or translucent. The permanently attached covermay further contain printing or embossing 210 (FIG. 56), such as for adesign, directions, or other indicia. For example, the permanentlyattached cover 209 (FIG. 56) may occupy the opening such that the wipesare only exposed by way of a strip along the bottom of the cartridge,through which they may be dispensed. In another example, the permanentlyattached cover 211 (FIG. 57) provides a space for dispensing the wipesat the bottom portion of the opening of the cartridge. The removableseal 212 (shown in a partially removed state) cooperates with thepermanently attached cover to provide a bacterial resistant seal untilthe removable seal is separated from the cartridge. Referring to FIG.58, the permanently attached cover may be initially present as a layer213 over the entire opening. This layer can be perforated 214, and abottom portion treated with an adhesive 215. A moisture-loss preventingseal 216 can then be placed over the layer, contacting the adhesive.When the moisture-loss preventing seal is removed, the portion of thelayer which is adhered to the seal is removed from the rest of the layerdue to tearing of the perforations. Referring to FIGS. 59 and 60, thepermanently attached cover may be a rigid lid 217 which can be hingedlyattached to the cartridge. The lid can be closed and snapped shut toprovide a slit through which the wipes can be dispensed. For example,the lid may have buttons 218 (FIG. 59), and the cartridge may havebutton holes 219 such that the mating of the lid and the cartridgecauses the lid to be locked onto the cartridge.

[0126] The permanently attached cover may be attached to the cartridgeby a variety of methods. For example, the attachment may be by way ofadhesives, heat welding, thermal bonding, ultrasonic sealing, RFsealing, or mechanical attachment such as crimping. The moisture-losspreventing seal may be attached to the cartridge and the permanentlyattached cover by way of adhesives, bonding, or sealing. It is desirablethat the strength of the bond between the moisture-loss preventing sealand the cartridge and the strength of the bond between the moisture-losspreventing seal and the permanently attached cover is less than thestrength of the bond between the cartridge and the permanently attachedcover. In this way, the consumer can easily remove the moisture-losspreventing seal without removing the permanently attached cover. Boththe permanently attached cover and the moisture-loss preventing sealcontact the lip around the cartridge.

[0127] The cover reduces the opening of the cartridge, and this may besufficient to prevent a roll of wipes from passing through the opening.Such a configuration discourages a consumer from placing another roll orstack of wet wipes in the cartridge after the original roll has beenfully dispensed. Although the wet wipes preferably contain preservativesand antimicrobial agents, prolonged use of a single cartridge with twoor more rolls of wet wipes may compromise the sterility of thedispenser, depending on the surrounding environment. The configurationalso discourages the removal of the roll of wipes from the cartridge.Wipes that are removed from the dispenser can become contaminated and/orcan lose their moisture content.

[0128]FIGS. 45A and 45B depict end views of one version of anasymmetrical cartridge 11. FIG. 45A is a view of a first end of thecartridge 11, looking into the axis of the roll 34 and showing asubstantially rectangular wall having side walls 39, 40 and a bottomwall 41 with an opening sealed by an impervious barrier 140 attached toa cartridge lip 31 that surrounds the opening. FIG. 45B provides a viewfrom the second end of the cartridge 11, showing a curved wall with sideportions 39, 40 and a curved bottom wall 41. The cartridge 11 is keyedto fit into the housing of a dispenser (not shown) in a manner thatensures proper orientation of the roll of wet wipes 34 within thehousing, and specifically ensures that the tail 36 of the roll 34 istoward the bottom of the housing when the cartridge 11 is placedtherein. For the cartridge 11 to be keyed to the housing of thedispenser (not shown), the housing (not shown) should have anasymmetrical shape corresponding to that of the cartridge, with one endbeing rounded and the other end substantially rectangular. Thetransition between the rounded and rectangular shapes may be gradual(e.g., morphing from one shape to the other) or sudden. When vieweddirectly from above (i.e., looking down on the cartridge 11 with theopening and impervious barrier 140 facing the viewer), the shape of thecartridge is asymmetrical with respect to rotation of the cartridge by180 degrees about the axis of sight (an axis normal to the axis of theroll 34, passing from the center of the impervious barrier 140 to thebottom wall 41). Thus, the cartridge 11 is asymmetrical for the purposesof the present invention. When used with a housing adapted to receivethe shape of the cartridge 11 in a keyed manner, the cartridge 11 willonly fit completely into the housing when it is placed therein with thecorrect orientation.

[0129]FIGS. 46A and 46B depict a related embodiment for an asymmetricalcartridge 11, wherein both ends of the cartridge are rounded andasymmetry in provided by the presence of a recess 142 on one end of thecartridge 11. The corresponding housing (not shown) would have aprotrusion on one end that could fit into the recess 142. Thus, thecartridge 11 would be keyed to fit into the housing of a dispenser inonly one orientation. FIG. 47 is a projection view of one version of thecartridge 11 shown in FIGS. 46A and 46B, wherein the recess 142 on oneside of the cartridge 11 linearly tapers away to provide an opposingside without a recess.

1. A container for wet wipes, comprising: a cartridge comprising a firstopening having a first rectangular clearance; the first rectangularclearance having a first length and a first width; a moisture-losspreventing seal; and a permanently attached cover over a portion of saidfirst opening; wherein said permanently attached cover forms a secondopening having a second rectangular clearance; the second rectangularclearance having a second length and a second width.
 2. The container ofclaim 1, wherein the second length is less than about 90% of the firstlength.
 3. The container of claim 1, wherein the second length is lessthan about 75% of the first length.
 4. The container of claim 1, whereinthe second length is less than about 60% of the first length.
 5. Thecontainer of claim 1, wherein the second length is less than about 50%of the first length.
 6. The container of claim 1, wherein the secondwidth is less than about 90% of the first width.
 7. The container ofclaim 1, wherein the second width is less than about 75% of the firstwidth.
 8. The container of claim 1, wherein the second width is lessthan about 60% of the first width.
 9. The container of claim 1, whereinthe second width is less than about 50% of the first width.
 10. Thecontainer of claim 1, wherein the second length is less than about 90%of the first length and the second width is less than about 90% of thefirst width.
 11. The container of claim 1, wherein the second length isless than about 75% of the first length and the second width is lessthan about 75% of the first width.
 12. The container of claim 1, whereinthe second length is less than about 60% of the first length and thesecond width is less than about 60% of the first width.
 13. Thecontainer of claim 1, wherein the second length is less than about 50%of the first length and the second width is less than about 50% of thefirst width.
 14. The container of claim 1, further comprising a roll ofwet wipes.
 15. A container for wet wipes, comprising: a cartridgecomprising an interior and an opening; the opening having a firstrectangular clearance; the first rectangular clearance having a firstlength and a first width; a roll of wet wipes in said interior; and apermanently attached cover over a portion of said opening; thepermanently attached cover forming a second opening having a secondrectangular clearance; the second rectangular clearance having a secondlength and a second width; wherein the roll is retained in the interior;and the wipes can be removed from the interior by unwinding the roll.16. The container of claim 15, wherein the second length is less thanabout 90% of the first length.
 17. The container of claim 15, whereinthe second length is less than about 75% of the first length.
 18. Thecontainer of claim 15, wherein the second length is less than about 60%of the first length.
 19. The container of claim 15, wherein the secondlength is less than about 50% of the first length.
 20. The container ofclaim 15, wherein the second width is less than about 90% of the firstwidth.
 21. The container of claim 15, wherein the second width is lessthan about 75% of the first width.
 22. The container of claim 15,wherein the second width is less than about 60% of the first width. 23.The container of claim 15, wherein the second width is less than about50% of the first width.
 24. The container of claim 15, wherein thesecond length is less than about 90% of the first length and the secondwidth is less than about 90% of the first width.
 25. The container ofclaim 15, wherein the second length is less than about 75% of the firstlength and the second width is less than about 75% of the first width.26. The container of claim 15, wherein the second length is less thanabout 60% of the first length and the second width is less than about60% of the first width.
 27. The container of claim 15, wherein thesecond length is less than about 50% of the first length and the secondwidth is less than about 50% of the first width.
 28. The container ofclaim 15, wherein the permanently attached cover is configured as astrip.
 29. The container of claim 15, wherein the permanently attachedcover is configured as a plurality of corner covers.
 30. The containerof claim 15, wherein the permanently attached cover is configured as asemicircularly shaped cover.
 31. The container of claim 15, wherein thepermanently attached cover comprises buttons and the cartridge comprisesbutton holes; the buttons and button holes coordinating to lock thepermanently attached cover to the cartridge.
 32. The container of claim15, further comprising a moisture-loss preventing seal.
 33. Thecontainer of claim 32, wherein the moisture-loss preventing seal coversthe second opening and is removably adhered to a portion of thepermanently attached cover.
 34. A container for wet wipes comprising:side walls having a top and a bottom; each side wall having a length anda depth; the tops of the side walls forming an opening having a firstlength and a first width; two opposed side walls corresponding to thefirst length of the container; a bottom wall joined to each side wall;the bottom wall having an curved section and a planar section; thecurved section having a first side and a second side; the planar sectionhaving a first side and a second side; the first side of the curvedsection being joined to the bottom of a first side wall; the second sideof the curved section being joined to the first side of the planarsection; the second side of the planar section being joined to thebottom of a second side wall that is opposed to the first side wall; alip; the lip joined to the top of a side wall; the lip extendingoutwardly at least about 5 mm from the top of a side wall; a permanentlyattached cover contacting at least a portion of the lip; and amoisture-loss preventing cover contacting at least a portion of the lip.35. The container of claim 34, wherein the permanently attached coverprovides a rectangular clearance having a second length and a secondwidth.
 36. The container of claim 34, wherein the second length is lessthan about 75% of the first length.
 37. The container of claim 34,wherein the second width is less than about 75% of the first width. 38.The container of claim 34, wherein the second length is less than about75% of the first length and the second width is less than about 75% ofthe first width.
 39. The container of claim 34, wherein the curvature ofthe bottom wall is about 42 to about 44 degrees.
 40. The container ofclaim 34, wherein the curvature of the bottom wall is about 40 to about45 degrees.
 41. The container of claim 34, wherein the side wallscorresponding to the width wise dimension of the container are taperedfrom the bottom toward the top, such that the distance between them isless at the bottom of the container.
 42. The container of claim 34,comprising a rib.
 43. The container of claim 34, comprising a pluralityof ribs, the ribs extending along the first wall, the curved bottomsection, the planar bottom section and at least partially along thesecond wall.
 44. A dispensing system for wipes, comprising: a dispenser,the dispenser comprising an interior; and a container shaped to fit intothe interior; the container comprising a cartridge, a permanentlyattached cover, a plurality of wet wipes, and a moisture-loss preventingseal.
 45. The dispensing system of claim 44, wherein the cartridgecomprises a first opening having a first rectangular clearance, thefirst rectangular clearance having a first length and a first width; thepermanently attached cover is situated over a portion of said firstopening to form a second opening having a second rectangular clearance,the second rectangular clearance having a second length and a secondwidth.
 46. The dispensing system of claim 44, wherein the second lengthis less than about 90% of the first length.
 47. The dispensing system ofclaim 44, wherein the second length is less than about 60% of the firstlength.
 48. The dispensing system of claim 44, wherein the second widthis less than about 90% of the first width.
 49. The dispensing system ofclaim 44, wherein the second width is less than about 60% of the firstwidth.
 50. The dispensing system of claim 44, wherein the second lengthis less than about 75% of the first length and the second width is lessthan about 75% of the first width.
 51. The dispensing system of claim44, further comprising a roll of wet wipes.
 52. The dispensing system ofclaim 44, wherein the interior and the container are shaped to fit in asingle orientation.
 53. The dispensing system of claim 44, wherein thedispenser, the cartridge, and the permanently attached cover togetherare capable of maintaining at least 95% of the moisture of wet wipes fora 14 day period at 73° F. and 50% relative humidity.